Panel Mounting System and Method

ABSTRACT

The present invention relates to a panel clamp securable to a variety of mounting mechanisms. The clamp includes first and second members, each having an edge extending beyond at least a portion of its side surface to form an overhang, and each includes a plurality of holes passing therethrough. When the overhang of the first member is fitted over a top surface of a panel and the overhang of the second member is fitted over a bottom surface of the panel, such that the plurality of holes in the first member is substantially aligned with the plurality of holes in the second member, mechanical fasteners can be inserted through the plurality of holes to secure the first and second members to the panel. An additional mechanical fastener is inserted through the clamp to secure the clamp to a mounting mechanism.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Application Nos. 61/459,267, filed Dec. 10, 2010,61/464,911, filed Mar. 11, 2011 and 61/571,210, filed Jun. 23, 2011, theentire disclosures of which are incorporated by reference herein as ifeach being set forth herein in its entirety.

BACKGROUND OF THE INVENTION

Due to the continued increase in cost and environmental impact of fossilfuels, solar panels have always been recognized in the alternativeenergy market as a commercially viable mechanism for capturing renewableenergy. However, one drawback to the use of solar panels is that solarpanels generally occupy a significant amount of space. So as not to useup desirable space, solar panels are often mounted on rooftops orexterior walls of existing buildings. In areas where ground space isplentiful, ground-mounted solar panel systems or arrays also have beenconstructed by mounting solar panels on supports.

Unfortunately, existing mounting systems are generally difficult toassemble and disassemble. In many cases, whole rows of solar panels mustbe removed simply to access the one panel in need of repair. Therefore,there is a need in the art for a system and method for mounting panelsthat allows for a cost-effective and improved speed of assembly anddisassembly, as well as for improved accessibility of individual panelswithin a solar panel array. The present invention satisfies this need.

SUMMARY OF THE INVENTION

The present invention relates to a panel clamp. The panel clamp includesfirst and second members, each having a top surface, a bottom surfaceand a side surface, wherein the top surface of each member includes anedge extending beyond at least a portion of its side surface to form anoverhang, and wherein a plurality of holes pass through the top andbottom surfaces of each member, and a plurality of mechanical fasteners,wherein, when the overhang of the first member is fitted over a topsurface of a panel and the overhang of the second member is fitted overa bottom surface of the panel, such that the plurality of holes in thefirst member is substantially aligned with the plurality of holes in thesecond member, the plurality of mechanical fasteners can be insertedthrough the plurality of holes to secure the first and second members tothe panel. In one embodiment, at least two of the aligned holes receivea mechanical fastener to secure the first and second members to thepanel. In another embodiment, at least one of the aligned holes receivesa mechanical fastener to secure the panel clamp to a surface mount. Inanother embodiment, the surface mount comprises a bracket. In anotherembodiment, the surface mount comprises a rail. In another embodiment,the panel is a photovoltaic (PV) module. In another embodiment, thepanel is a liquid crystal display (LCD).

The present invention also relates to a system for securing a panel to asurface. The system includes a panel clamp comprising first and secondmembers, each having a top surface, a bottom surface and a side surface,wherein the top surface of each member includes an edge extending beyondat least a portion of its side surface to form an overhang, and whereina plurality of holes pass through the top and bottom surfaces of eachmember, a plurality of mechanical fasteners, and a mount comprising asurface anchoring plate, a panel clamp anchoring plate and a supportelement connecting the surface anchoring plate to the clamp anchoringplate, wherein the surface anchoring plate and the clamp anchoring plateeach have a plurality of holes therethrough, wherein, when the overhangof the first member is fitted over a top surface of a panel and theoverhang of the second member is fitted over a bottom surface of thepanel, such that the plurality of holes in the first member issubstantially aligned with the plurality of holes in the second member,at least one of the mechanical fasteners can be inserted through theplurality of holes to secure the first and second members to the panelto form a panel clamp, and wherein the mount is secured to a surface byinserting at least one of the mechanical fasteners through the holes ofthe surface anchoring plate and into the surface, and the panel clamp issecured to the mount by inserting at least one of the mechanicalfasteners through at least one of the aligned holes of the panel clampinto at least one of the holes in the clamp anchoring plate. In oneembodiment, at least two of the mechanical fasteners are inserted tosecure the first and second members to the panel. In another embodiment,the panel is a photovoltaic (PV) module. In another embodiment, thepanel is a liquid crystal display (LCD).

In another embodiment, the distance between the surface anchoring plateand the clamp anchoring plate is adjustable. In another embodiment, thesupport element is a bolt that engages a threaded hole in either or bothof the surface anchoring plate and the clamp anchoring plate, andadjustment is made by either rotation of the bolt in one or both of theholes in the surface anchoring plate and the clamp anchoring plate, orby rotation of either the surface anchoring plate or the clamp anchoringplate about the bolt.

The present invention also relates to an adjustable panel mount. Themount includes a mounting arm having a front surface and a back surface,and a distal end that includes first and second holes passing throughthe front and back surfaces thereof, a mounting head having a frontplate, a back plate and a top plate connecting the front and backplates, such that a space between the front and back plates is formedunderneath the top plate, wherein the top plate has a plurality of holespassing therethrough, and the front and back plates have a plurality ofaligned holes passing therethrough, and a plurality of mechanicalfasteners, wherein, when the front and back plates of the mounting headare fitted overtop or within the distal end of the mounting arm and atleast two of the aligned holes of the front and back plates of themounting head are also aligned with the first and second holes of themounting arm, a first mechanical fastener can be inserted through thealigned holes incorporating the first hole of the mounting arm to securethe mounting head to the mounting arm, and a second mechanical fastenercan be inserted through the aligned holes incorporating the second holeof the mounting arm to position the top plate of the mounting head at adesired angle. In one embodiment, at least one of the aligned holes inthe front and back plates of the mounting head provide different anglesof the top plate of the mounting head. In another embodiment, the mountincludes a panel clamp, the panel clamp comprising first and secondmembers, each having a top surface, a bottom surface and a side surface,wherein the top surface of each member includes an edge extending beyondat least a portion of its side surface to form an overhang, and whereina plurality of holes pass through the top and bottom surfaces of eachmember, a plurality of mechanical fasteners, wherein, when the overhangof the first member is fitted over a top surface of a panel and theoverhang of the second member is fitted over a bottom surface of thepanel, such that the plurality of holes in the first member issubstantially aligned with the plurality of holes in the second member,at least one of the mechanical fasteners can be inserted through theplurality of holes of the first and second members to secure the firstand second members to the panel to form a panel clamp, and wherein thepanel clamp is secured to the top plate of the mounting head byinserting at least one of the mechanical fasteners through at least oneof the aligned holes of the panel clamp into at least one of the holesin the top plate of the mounting head.

The present invention also relates to a system for securing a panel to amount. The system includes a panel clamp comprising first and secondmembers, each having a top surface, a bottom surface and a side surface,wherein the top surface of each member includes an edge extending beyondat least a portion of its side surface to form an overhang, and whereina plurality of holes pass through the top and bottom surfaces of eachmember, a plurality of mechanical fasteners, and a mount that includes aframe having a base, side walls and opposing grooves extending inwardlytoward each other, and a rail plate having flange portions on opposingsides of the rail plate, such that the flange portion on each side ofthe rail plate fits slidably within the opposing grooves of the frame,and wherein the rail plate includes a plurality of holes passingtherethrough, wherein, when the overhang of the first member is fittedover a top surface of a panel and the overhang of the second member isfitted over a bottom surface of the panel, such that the plurality ofholes in the first member is substantially aligned with the plurality ofholes in the second member, at least one of the mechanical fasteners canbe inserted through the plurality of holes to secure the first andsecond members to the panel to form a panel clamp, and wherein the panelclamp is secured to the mount by inserting at least one of themechanical fasteners through at least one of the aligned holes of thepanel clamp into at least one of the holes in the rail plate. In anotherembodiment, the base of the frame further includes at least one holepassing therethrough, such that a mechanical fastener may be insertedthrough the at least one hole of the frame base to secure the mount to arail of a second mount.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there are depicted in thedrawings certain embodiments of the invention. However, the invention isnot limited to the precise arrangements and instrumentalities of theembodiments depicted in the drawings.

FIG. 1 is a schematic perspective view of an exemplary panel clampingand mounting mechanism, according to an aspect of the present invention.

FIG. 2, comprising FIGS. 2A-2C, is an exemplary clamping mechanism,according to an aspect of the present invention. FIG. 2A is aperspective view of the top and bottom plates of the clamping mechanism,FIG. 2B is a side view of a clamp plate, and FIG. 2C is a front view ofa clamp plate.

FIG. 3, comprising FIGS. 3A-3B, is an exemplary adjustable mountingmechanism, according to an aspect of the present invention. FIG. 3A is aperspective view of an adjustable mount. FIG. 3B is a side view of theadjustable mount of FIG. 3A.

FIG. 4 is a side view of an exemplary panel clamping and mountingmechanism, according to an aspect of the present invention, where themounting head is adjustable.

FIG. 5, comprising FIGS. 5A-5B, is an exemplary adjustable mountinghead, according to an aspect of the present invention. FIG. 5A is afront view of the adjustable mounting head, and FIG. 5B is a perspectiveview of the adjustable mounting head.

FIG. 6, comprising FIGS. 6A-6B, is an exemplary mounting arm for theadjustable mounting head of FIG. 5, FIG. 6A is a front view of themounting arm, and FIG. 6B is a side view of the mounting arm.

FIG. 7 is a side view of an exemplary panel clamping and rail mountingmechanism, according to an aspect of the present invention.

FIG. 8 is a perspective view of an exemplary rail mounting mechanism fora large scale utility frame, according to an aspect of the presentinvention.

FIG. 9 is a perspective view of an exemplary panel array on the railmounting mechanism of FIG. 8, according to an aspect of the presentinvention.

FIG. 10 is a front view of an exemplary panel array attached tosupportive legs held down with a ballast pan and weight, according to anaspect of the present invention.

FIG. 11 is a side view of an exemplary panel array attached tosupportive legs that are buried into the mounting surface, according toan aspect of the present invention.

FIG. 12 is a perspective view of an exemplary panel array on a railmounting mechanism attached to support legs, according to an aspect ofthe present invention.

DETAILED DESCRIPTION

It is to be understood that the figures and descriptions of the presentinvention have been simplified to illustrate elements that are relevantfor a clear understanding of the present invention, while eliminating,for the purpose of clarity, many other elements found in panel mountingsystems and methods. Those of ordinary skill in the art may recognizethat other elements and/or steps are desirable and/or required inimplementing the present invention. However, because such elements andsteps are well known in the art, and because they do not facilitate abetter understanding of the present invention, a discussion of suchelements and steps is not provided herein. The disclosure herein isdirected to all such variations and modifications to such elements andmethods known to those skilled in the art.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, the preferred methodsand materials are described.

As used herein, each of the following terms has the meaning associatedwith it in this section.

The articles “a” and “an” are used herein to refer to one or to morethan one (i.e., to at least one) of the grammatical object of thearticle. By way of example, “an element” means one element or more thanone element.

“About” as used herein when referring to a measurable value such as anamount, a temporal duration, and the like, is meant to encompassvariations of ±20% or ±10%, more preferably ±5%, even more preferably±1%, and still more preferably ±0.1% from the specified value, as suchvariations are appropriate to perform the disclosed methods.

“Holes” as used herein may include any opening suitable for receiving abolt, pin or other mechanical fastener for securing two componentstogether. Such holes may be smooth, so as to receive a pin, or they maybe threaded, so as to receive a screw or bolt. Holes should not beconstrued as being limited to any particular type of hole designed forreceiving a particular mechanical component.

“Mechanical fastener” as used herein may include any device that holdstwo or more objects together. Exemplary mechanical fasteners are,without limitation, a bolt, screw, rivet or pin.

“Panel” as used herein may include any structure having a perimeter withat least one edge having a portion that is substantially linear.Generally, a panel is rectangular in shape. Exemplary panels arephotovoltaic (PV) modules, liquid-crystal displays (LCDs), and othergenerally rectangular objects.

“Surface” as used herein refers to the outermost or topmost boundary ofan object. A surface may be a final surface to which a panel or panelsis to be mounted to, such as a roof, wall or the ground, or it may be aportion of a component of the present invention, such as a top or bottomsurface of a clamp plate or member.

Throughout this disclosure, various aspects of the invention can bepresented in a range format. It should be understood that thedescription in range format is merely for convenience and brevity andshould not be construed as an inflexible limitation on the scope of theinvention. Accordingly, the description of a range should be consideredto have specifically disclosed all the possible subranges as well asindividual numerical values within that range. For example, descriptionof a range such as from 1 to 6 should be considered to have specificallydisclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numberswithin that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any wholeand partial increments therebetween. This applies regardless of thebreadth of the range.

The present invention includes a system that is designed for mountingvirtually any size panel, such as a PV module or LCD, onto a surface,such as on the ground, on the roof or on an interior or exterior wall ofa commercial or residential building. The surface may be flat, graded ormulti-tiered, and may be horizontal, vertical, or at any angletherebetween. Further, the surface may form part of a mobile object,such as a truck, recreational vehicle (RV), buss, car, boat, train,plane, or any object attached thereto. As contemplated herein, thepresent invention is not limited to the mounting of PV modules, butrather is suitable for mounting any sort of panel or structure having atleast one substantially linear edge. Thus, while the exemplaryembodiments relate particularly to the mounting of PV modules, it shouldbe appreciated that any sort of panel may be mounted as described andillustrated herein.

Generally, the system of the present invention includes two primarycomponents. The first component includes a clamping mechanism thatfastens onto the PV module, while the second component includes amounting mechanism that fastens both to the clamping mechanism and tothe desired roof or wall surface.

In an exemplary embodiment, the clamping mechanism may include twoplates and two bolts. In this example, one plate rests on top and alongan edge of the outer frame of the PV module, while the second platerests on the corresponding bottom portion of the outer frame of the PVmodule, such that, when fastened together by the two screws, the twoplates form a clamp onto the outer frame of the PV module. Further, theclamp can be adjusted according to both the thickness of the panelframe, as well as its position anywhere along the perimeter of the frameof the PV module. The clamping mechanism generally includes three holesfor tightening the clamp as well as for attaching the clamp to themounting mechanism as described herein. In other embodiments, theclamping mechanism may include additional holes in the plates, such as4, 5, 6, 7, 8, 9, 10 or any desired number. In an embodiment includingthree holes, two of the holes are used for the screws to fasten the twoplates together on the PV module frame, while the third hole is used fora third bolt to go through and fasten the clamping mechanism to themounting mechanism, which may be, for example, a mounting bracket ormounting rail, as described in further detail herein. There is nolimitation to the positioning of the holes, either for tightening of theclamping mechanism or for attaching the clamping mechanism to thedesired mounting mechanism.

As illustrated in FIGS. 1 and 2, the present invention includes aclamping mechanism 10 suitable for attachment to a panel 5, such as asolar panel, and is separately attachable to a mount 30, for mountingpanel 5 to a surface, such as the roof or wall of a building. Ascontemplated herein, the present invention is suitable for mounting on asurface having any angle, such as a substantially horizontal or 0°surface, a substantially vertical or 90° surface, or any angle or pitchbetween 0-90°.

As shown in FIGS. 1 and 2A, clamping mechanism 10 includes a first ortop plate or member 12 and a second or bottom plate or member 14. Bothtop and bottom plates 12 and 14 have matching holes 15, 17 and 19passing through plates 12 and 14, such that holes 15, 17 and 19 of eachplate are aligned when clamping panel 5. In the embodiment of FIGS. 1and 2, holes 15 and 17 are suitable for securing top and bottom clampingplates 12 and 14 together with bolts, while hole 19 is suitable forsecuring the assembled clamp to a mounting mechanism that is securableto the desired surface. Plates 12 and 14 also include an extended lip oredge 13, which serves to extend slightly over the top and bottomsurfaces of panel 5 to create an enhanced grasping area for engaging orfitting onto panel 5.

Clamping mechanism 10 engages and clamps panel 5 as follows. Top plate12 is positioned such that its extended edge 13 rests on the front faceof panel 5, with the remainder of top plate 12 aligned along the side ofpanel 5, with holes 15, 17 and 19 running substantially vertical orotherwise substantially perpendicular to the plane of the front face ofpanel 5. Bottom plate 14 is then positioned such that its extended edge13 rests on the bottom face of panel 5 and the remainder of bottom plate14 is substantially underneath top plate 12, such that correspondingholes 15, 17 and 19 are aligned. Bolts are inserted through holes 15 and17 of both top and bottom plates 12 and 14 to securely attach the clampto panel 5. Alternatively, plates 12 and 14 may be positioned such thatthey bridge a gap between two adjacent panels, to secure the two panelstogether directly at their adjacent edges when positioned in a panelarray. Depending on the type of panel and use of clamping mechanism 10,the clamp can be secured tightly to panel 5, such that the clamp cannotmove along the side of panel 5, or it can be secured in such a way thatit can slide along the length of panel 5 without falling off. It shouldbe appreciated that clamping mechanism 10 may further include any sortof textured surface on the portions of top and bottom plates 12 and 14that contact panel 5, such as extended edges 13 forming an overhang, toimprove any of a friction grip, or the ability to slide along the sideof panel 5, as would be understood by those skilled in the art. Forexample, such textured surface may include small ridges, “teeth” orother contoured surface to improve grasping of the panel. Such regionsmay further include secondary materials to provide enhanced grasping,such as an adhesive or other chemical coating, or a rubber layer.

As contemplated herein, clamping mechanism 10 may come in virtually anylength, such as any length from 1 in. to 10 ft., more preferably anylength from 4 in. to 12 in., for example, where the desired length willdepend on the size and/or type of panel being mounted. Top and bottomplates 12 and 14 may be constructed from any suitable building materialthat provides sufficient strength, rigidity and durability, such asaluminum and other metals and metal alloys, galvanized metals/alloys,moldable polymers and polymer blends, rubber and the like. All bolts,pins or other mechanical fasteners may be of a standard size andcommercially available, such as bolts ranging from ¼ to ½ in.Consequently, the diameter of any particular hole will be based on thedesired mechanical fastener to be received therein.

Clamping mechanism 10 is designed to engage and/or be secured to avariety of mounting mechanisms. By having clamping mechanism 10 separatefrom the mounting mechanism, an installer has the ability to remove aparticular clamped panel at any time by removing a single bolt, withoutother panels being affected and without disrupting the mount as securedto the desired surface.

For example, referring again to FIG. 1, mount 30 may generally include asurface anchoring plate 34 for anchoring the mount to a roof, wall orother surface, a clamp anchoring plate 32 for securing clampingmechanism 10, and a support element 33 (also referred to herein as aweb, crossbeam, beam, etc.), transversing plates 32 and 34 for providingseparation and supportive strength between surface anchoring plate 34and clamp anchoring plate 32. While plates 32 and 34 are illustrated asbeing substantially parallel with support element 33 runningsubstantially perpendicular thereto, it should be appreciated that clampanchoring plate 32 may be positioned at any desired angle compared tosurface anchoring plate 34 or to support element 33. For example, clampanchoring plate 32 may be approximately 15°, 30°, 45°, 60°, 75°, 90°,105°, 120°, 135°, 150° or 165° with respect to surface anchoring plate34. The length of the surface anchoring plate may be of any desirablesize, such as ranging from 2 ft to 4 ft, depending on the size of the PVmodule and the number of such modules to be mounted. Surface anchoringplate 34 may be wide enough for a standard or custom ballast pan to siton top of and to hold additional weight, as would be understood by thoseskilled in the art.

As illustrated in FIG. 1, surface anchoring plate 34 includes two holes(not shown) through which lag bolts 36 and 38 may be inserted tosecurely anchor or otherwise fasten mount 30 to the roof or wallsurface. The number and/or size of the holes in surface anchoring plate34 is not limited to any particular number or size, and thus mayalternatively include 1, 3, 4, 5, 6, 8, or any number of holes throughwhich one or more bolts may be inserted to anchor mount 30 to thedesired surface. The size of the holes should be commensurate with thetype of bolt being inserted therethrough. Furthermore, the holes may bepositioned anywhere in surface anchoring plate 34.

Clamp anchoring plate 32 also includes a series of holes 31 forreceiving bolt(s) 20 for securing clamping mechanism 10 to mount 30. Inone example, clamp anchoring plate 32 includes two rows of 5 holesrunning along the length of clamp anchoring plate 32 in parallel. Inthis example, each row of 5 holes may is suitable for securing aclamping mechanism 10, such that two clamping mechanisms 10 may besecured, back-to-back, to clamp anchoring plate 32 at the same time. Byhaving a series of holes in a row, a panel installer can elect whichhole in the row is most suitable for attaching clamping mechanism 10 tomount 30, thereby providing the installer the ability to adjust thepositioning of clamping mechanism 10 not only on the panel itself, butalso with respect to where it is fastened to mount 30.

In another embodiment, mount 30 may be adjustable, such that aninstaller has the option to adjust the height of the panel from thesurface, for example, to compensate for the warping of wood roofs, or toallow more heat to pass through the solar panels for more efficiency.For example, as shown in FIGS. 3A and 3B, clamp anchoring plate 32 andsurface anchoring plate 34 are separate components held together by oneor more bolts 39, which may be a ½ inch thread bolt, for example. Thedistance between plates 32 and 34 can be adjusted via advancing orretracting bolt 39 through the threaded holes of either or both plates32 and 34, as would be understood by those skilled in the art. In otherembodiments, such adjustment can be accomplished by other mechanicalmeans as would be understood by those skilled in the art. For example,the support element between plates 32 and 34 may alternatively be atelescoping arm or beam, such that the distance between plates 32 and 34may likewise be adjustable.

In another exemplary embodiment, the mounting mechanism can includemeans for “tilting” the attached panel, or otherwise adjusting the angleat which the panel is positioned relative to the surface mountedthereto. For example, as seen in FIG. 4, clamping mechanism 10, beingsecured to panel 5, is fastened to adjustable mounting head 45, which isalso attached to mounting arm 42. Mounting arm 42 is likewise secured tothe desired surface 41 via any standard means as would be understood bythose skilled in the art, including a standard bracket 40 bolted tosurface 41, by welding or any other attachment mechanism. In still otherembodiments, mounting arm 42 and surface 41 may be integrated into asingle “T” bar construct, which is itself secured to a desired surface.By adjusting the position of mounting head 45, the angle of panel 5 canbe altered relative to the desired surface.

As shown in FIGS. 5A and 5B, adjustable mounting head 45 may includefront and back plates 43 attached together via top plate 44 to whichclamping mechanism 10 is attached via holes 48. While plates 43 areillustrated as being rounded, plates 43 may be any shape, includingoval, square, rectangular, triangular or any other shape desired. Frontand back plates 43 have corresponding or matching holes 47 and 49 forengaging and attaching to mounting arm 42. Similarly, mounting arm 42has corresponding holes 50 and 51 for attachment to adjustable mountinghead 45, has shown in FIGS. 6A and 6B. To attach mounting head 45 tomounting arm 42, the attachment end 52 of mounting arm 42 containingholes 50 and 51 is fitted within (or outside of) front and back plates43 of mounting head 45, such that hole 49 of mounting head 45 is alignedwith hole 50 of mounting arm 42, and at least one of holes 47 ofmounting head 45 is aligned with hole 51 of mounting arm 42. Mountingarm 42 may include extended edges or plates, as illustrated in FIG. 6B,which may or may not include holes 50 or 51, or mounting arm 42 may notinclude any extended edges or plates. A bolt or pin may be insertedthrough holes 49 and 50 to secure mounting head 45 to mounting arm 42,such that mounting head 42 can rotate or pivot freely around the bolt orpin. A second bolt or pin may be inserted through one of holes 47 andthrough hole 51 to lock the mounting head into place. By selecting aparticular hole 47 to insert the bolt or pin through, the installer canthereby select the angle at which the panel is positioned relative tothe surface. Mounting head 45 can include markings identifying whatangles are achieved by selecting any particular hole 47. For example,each hole 47 can represent a particular preset angle between andincluding 0° and 180°, such as 0°, 15°, 30°, 45°, 60°, 75°, 90°, 105°,120°, 135°, 150°, 165° and 180°, by non-limiting example. It should beappreciated that any number of holes 47 may be used, each representingany panel angle desired. In an alternative embodiment, the adjustingmeans may include or be replaced by other mechanical features foraccomplishing the same goal, such mechanisms including spring loadedpins or spring actuated levers, detents and the like to divide therotation of mounting head 45 into discrete increments, or otherwiseresist or arrest such rotation at desired angles.

Holes 48 on top plate 44 of mounting head 45 are positioned to receiveclamping mechanism 10 in a similar manner as described for attachment toclamp anchoring plate 32 of mount 30. Top plate 44 also includes aseries of holes 48 for receiving a bolt for securing clamping mechanism10 to top plate 44 of mounting head 45. Like the clamp anchoring plateof mount 30, top plate 44 may include two rows of 2, 3, 4, 5, 6, 7, 8,9, 10 or any other number of holes running along the length of top plate44 in parallel. Each row of holes is suitable for securing a clampingmechanism 10, such that two clamping mechanisms 10 may be secured,back-to-back, to top plate 44 of mounting head 45 at the same time. Byhaving a series of holes in a row, a panel installer can elect whichhole in the row is most suitable for attaching clamping mechanism 10 tomounting head 45, thereby providing the installer the ability to adjustthe positioning of clamping mechanism 10 not only on the panel itself,but also with respect to where it is fastened to the mount.

In another embodiment, clamping mechanism 10 may be attached to a railmount. The mounting rail allows clamping mechanism 10 and attached panel5 to slide within the rail system. As shown in FIG. 7, the rail mount 60includes a base frame 62 having two grooves 64, in which a flange 68 oneither side of sliding rail 66 fits, such that when flange 68 of rail 66is positioned within grooves 64, rail 66 may slide along the length offrame 62. Rail 66 further includes an attachment point 67 which mayinclude a series of holes (not shown) through which one or more bolts 20of clamping mechanism 10 may engage rail 66. Similar to the previouslydescribed mounts, the number and position of holes for receiving bolt 20of clamping mechanism 10 can be any number and located in any position.

In an alternative embodiment, frame 62 may have multiple rails 66positioned along its length, such that each rail 66 within frame 62 mayhave one or more panels attached to them. As contemplated herein, thereis no limitation to the number of rails within rail mount 60, and thereis no limitation to the number of panels (attached by the clampingmechanisms) secured to each particular rail.

As shown in FIG. 7, when bolt 20 is secured tightly to rail mount 60,clamping mechanism 10 is forcibly held against frame 62, thereby holdingclamping mechanism 10 and rail 66 in place. If bolt 20 is loosened,clamping mechanism 10 and rail 66 may freely slide along the length offrame 62. In alternative embodiments, the body of rail 66 (not includingflange 68) may be thicker and extend outward from the outer face offrame 62, such that when clamping mechanism 10 is secured tightly torail 66 via bolt 20, rail 66 may still slide freely along the length offrame 62.

The rail mount is particularly useful when assembling the base for alarge scale utility frame, because there is no need to manufactureadditional parts. For example, as shown in FIGS. 8 and 9, an installercan secure one rail mount 70 into another rail mount 60. Rail mount 60,being similar to and having like parts as described in FIG. 7, mayinclude two holes (not shown) for receiving bolts 76, instead of bolt 20from a clamping mechanism. In this example, bolts 76 are used to securethe base of frame 72 onto rail 66 of rail mount 60 at any angle desired,such that rail mount 70 runs substantially perpendicular to rail mount60, or at any angle between and including 0° and 180°, as desired. Asshown in FIG. 9, a panel array 80 can be assembled, where each panel 5has at least one clamping mechanism 10 attached thereto, which is inturn attached to rail mounts 70 in the same manner as previouslydescribed. Panel array 80 may be either attached to a plurality ofmounting arms 82 and secured to the desired surface, or alternatively,panel array 80 can be directly secured to the desired surface via railmounts 60. In a further embodiment, rail mounts can be attached to othermounting mechanisms described herein, such as to mount 30 of FIG. 1. Inthe event mounting arms 82 are used, such arms may be anchored to therail mount and/or to the surface by standard attachment mechanisms aswould be understood by those skilled in the art. Mounting arms 82 mayfurther be adjustable in height, such as by telescoping means, forexample, as would also be understood by those skilled in the art.

In another embodiment, clamping mechanism 10 can be fastened to astandard joint or bracket that is further attached to a plurality ofsupportive legs. As shown in FIG. 10, clamping mechanism 10 may besecured to panels 5, and further attached to support legs 93 by a joint,bracket, or other attachment mechanism (not shown). The size of the legjoint can range from 1 inch to 10 feet in length. The joint may also beused for single or double leg 93 mounting. Support legs 93 may rangefrom 1 to 20 feet in length, and may be fastened to the surface bybolts, or alternatively to a ballast pan 94 for holding weights 92, suchas concrete blocks. Support legs 93 may further be a “T” bar support,such that the crossbeam of the “T” bar is positioned on the desiredmounting surface, and ballast pan 94 rests overtop the crossbeamcomponent of support leg 93, as shown in FIG. 10. Alternatively, ballastpan 94 may include grooves where metal plates can slide through forweights 92 to hold down supportive legs 93. In other embodiments, theballast pan can be replaced by a series of one or more rods, wherein therods can pass through the support legs or overtop the support legs, suchthat weights 92 can be positioned overtop the rods to hold down andsupport the structure. If an array of panels is desired and multiplemounts/support legs are used, the rods could pass through the legs ofeach mounting mechanism, with the rods only being secured directly tothe desired surface at either end of the array. This would reduce thenumber of times an installer would need to puncture a roof to supportthe panel array, for example. In still other embodiments, such as thatshown in FIG. 11, supportive legs 93 may be buried into the desiredsurface (98). In the embodiments of FIGS. 11 and 12, supportive legs 93may be attached to a rail mount system, as previously described.

Any of the mounting mechanisms described herein may be constructed fromany suitable building material that provides sufficient strength,rigidity and durability, such as metals, galvanized metals, moldablepolymers and polymer blends, rubber and the like. All bolts, pins orother mechanical fastening components may be customized or of a standardsize and commercially available. Consequently, the diameter of anyparticular hole will be based on the desired bolt or pin to be receivedtherein.

In other embodiments, the clamping mechanism and/or mounting mechanismmay include a grounding lug. In other embodiments, the clamping and/ormounting mechanism may include a microinverter in communicationtherewith. In further alternative embodiments, the clamping mechanismcan be integrated into any of the mounting mechanisms as describedhereinthroughout, such that the clamp and mount form a single piece orunit. In still other embodiments, the clamping mechanism may be slidablyattached to a mount, such as by a fitted flange and groove slidingsystem. It should be appreciated that the clamping mechanism mayalternatively be attached or integrated with mount by any meansunderstood by those skilled in the art. In this way, the single unitclamp-mount can be securely fastened to the desired surface, and thepanel can be placed within the loose clamp portion by the installer.Once the panel is positioned in the desired spot, the installer cantighten the clamp to secure the panel to the mount.

The disclosures of each and every patent, patent application, andpublication cited herein are hereby incorporated herein by reference intheir entirety.

While this invention has been disclosed with reference to specificembodiments, it is apparent that other embodiments and variations ofthis invention may be devised by others skilled in the art withoutdeparting from the true spirit and scope of the invention. The appendedclaims are intended to be construed to include all such embodiments andequivalent variations.

1. A panel clamp, comprising: first and second members, each having atop surface, a bottom surface and a side surface, wherein the topsurface of each member includes au edge extending beyond at least aportion of its side surface to form an overhang, and wherein a pluralityof holes pass through the top and bottom surfaces of each member; and aplurality of mechanical fasteners; wherein, when the overhang of thefirst member is fitted over a top surface of a panel and the overhang ofthe second member is fitted over a bottom surface of the panel, suchthat the plurality of holes in the first member is substantially alignedwith the plurality of holes in the second member, the plurality ofmechanical fasteners can be inserted through the plurality of holes tosecure the first and second members to the panel.
 2. The panel clamp ofclaim 1, wherein at least two of the aligned holes receives a mechanicalfastener to secure the first and second members to the panel.
 3. Thepanel clamp of claim 2, wherein at least one of the aligned holesreceives a mechanical fastener to secure the panel clamp to a surfacemount.
 4. The panel clamp of claim 3, wherein the surface mountcomprises a bracket.
 5. The panel clamp of claim 3, wherein the surfacemount comprises a rail.
 6. The panel clamp of claim 1, wherein the panelis a photovoltaic (PV) module.
 7. The panel clamp of claim 1, whereinthe panel is a liquid crystal display (LCD).
 8. A system for securing apanel to a surface, comprising: a panel clamp comprising first andsecond members, each having a top surface, a bottom surface and a sidesurface, wherein the top surface of each member includes an edgeextending beyond at least a portion of its side surface to form anoverhang, and wherein a plurality of holes pass through the top andbottom surfaces of each member; a plurality of mechanical fasteners; anda mount comprising a surface anchoring plate, a panel clamp anchoringplate and a support element connecting the surface anchoring plate tothe clamp anchoring plate, wherein the surface anchoring plate and theclamp anchoring plate each have a plurality of holes therethrough;wherein, when the overhang of the first member is fitted over a topsurface of a panel and the overhang of the second member is fitted overa bottom surface of the panel, such that the plurality of holes in thefirst member is substantially aligned with the plurality of holes in thesecond member, at least one of the mechanical fasteners can be insertedthrough the plurality of holes to secure the first and second members tothe panel to form a panel clamp; and wherein the mount is secured to asurface by inserting at least one of the mechanical fasteners throughthe holes of the surface anchoring plate and into the surface, and thepanel clamp is secured to the mount by inserting at least one of themechanical fasteners through at least one of the aligned holes of thepanel clamp into at least one of the holes in the clamp anchoring plate.9. The system of claim 8, wherein at least two of the mechanicalfasteners are inserted to secure the first and second members to thepanel.
 10. The system of claim 8, wherein the panel is a photovoltaic(PV) module.
 11. The system of claim 8, wherein the panel is a liquidcrystal display (LCD).
 12. The system of claim 8, wherein the distancebetween the surface anchoring plate and the clamp anchoring plate isadjustable.
 13. The system of claim 12, wherein the support element is abolt that engages a threaded hole in either or both of the surfaceanchoring plate and the clamp anchoring plate, and adjustment is made byeither rotation of the bolt in one or both of the holes in the surfaceanchoring plate and the clamp anchoring plate, or by rotation of eitherthe surface anchoring plate or the clamp anchoring plate about the bolt.14. An adjustable panel mount, comprising: a mounting arm having a frontsurface and a back surface, and a distal end that includes first andsecond holes passing through the front and back surfaces thereof; amounting head having a front plate, a back plate and a top plateconnecting the front and back plates, such that a space between thefront and back plates is formed underneath the top plate, wherein thetop plate has a plurality of holes passing therethrough, and the frontand back plates have a plurality of aligned holes passing therethrough;and a plurality of mechanical fasteners; wherein, when the front andback plates of the mounting head are fitted overtop or within the distalend of the mounting arm and at least two of the aligned holes of thefront and back plates of the mounting head are also aligned with thefirst and second holes of the mounting arm, a first mechanical fastenercan be inserted through the aligned holes incorporating the first holeof the mounting arm to secure the mounting head to the mounting arm, anda second mechanical fastener can be inserted through the aligned holesincorporating the second hole of the mounting arm to position the topplate of the mounting head at a desired angle.
 15. The adjustable panelmount of claim 14, wherein at least one of the aligned holes in thefront and back plates of the mounting head provide different angles ofthe top plate of the mounting head.
 16. The adjustable panel mount ofclaim 14, further comprising a panel clamp, the panel clamp comprisingfirst and second members, each having a top surface, a bottom surfaceand a side surface, wherein the top surface of each member includes anedge extending beyond at least a portion of its side surface to form anoverhang, and wherein a plurality of holes pass through the top andbottom surfaces of each member; a plurality of mechanical fasteners;wherein, when the overhang of the first member is fitted over a topsurface of a panel and the overhang of the second member is fitted overa bottom surface of the panel, such that the plurality of holes in thefirst member is substantially aligned with the plurality of holes in thesecond member, at least one of the mechanical fasteners can be insertedthrough the plurality of holes of the first and second members to securethe first and second members to the panel to form a panel clamp; andwherein the panel clamp is secured to the top plate of the mounting headby inserting at least one of the mechanical fasteners through at leastone of the aligned holes of the panel clamp into at least one of theholes in the top plate of the mounting head.
 17. The adjustable panelmount of claim 16, wherein the panel is a photovoltaic (PV) module. 18.The adjustable panel mount of claim 16, wherein the panel is a liquidcrystal display (LCD).
 19. A system for securing a panel to a mount,comprising: a panel clamp comprising first and second members, eachhaving a top surface, a bottom surface and a side surface, wherein thetop surface of each member includes an edge extending beyond at least aportion of its side surface to form an overhang, and wherein a pluralityof holes pass through the top and bottom surfaces of each member; aplurality of mechanical fasteners; and a mount comprising: a framehaving a base, side walls and opposing grooves extending inwardly towardeach other; and a rail plate having flange portions on opposing sides ofthe rail plate, such that the flange portion on each side of the railplate fits slidably within the opposing grooves of the frame, andwherein the rail plate includes a plurality of holes passingtherethrough; wherein, when the overhang of the first member is fittedover a top surface of a panel and the overhang of the second member isfitted over a bottom surface of the panel, such that the plurality ofholes in the first member is substantially aligned with the plurality ofholes in the second member, at least one of the mechanical fasteners canbe inserted through the plurality of holes to secure the first andsecond members to the panel to form a panel clamp; and wherein the panelclamp is secured to the mount by inserting at least one of themechanical fasteners through at least one of the aligned holes of thepanel clamp into at least one of the holes in the rail plate.
 20. Thesystem of claim 19, wherein at least two of the mechanical fasteners areinserted to secure the first and second members to the panel.
 21. Thesystem of claim 19, wherein the panel is a photovoltaic (PV) module. 22.The system of claim 19, wherein the panel is a liquid crystal display(LCD).
 23. The system of claim 19, wherein the base of the frame furtherincludes at least one hole passing therethrough, such that a mechanicalfastener may be inserted through the at least one hole of the frame baseto secure the mount to a rail of a second mount.